Yoga mat with suction pattern

ABSTRACT

A PVC yoga mat with a suction pattern having a surface layer, two medial layers and a bottom layer. The surface layer can be a PVC film covering the first medial layer, and the medial layers and bottom layer can be PVC foam sheets. The first medial layer is a micro-foaming layer, and the second medial layer and the bottom layer are foaming layers. The surface layer, the first medial layer, the second medial layer and the bottom layer are combined into one body, and an anti-skid surface pattern is formed on the surface layer and the first medial layer.

INTRODUCTION/BACKGROUND

Yoga mats are relatively thin, soft mats providing a clean, high-traction surface on which to perform yoga exercises. The mats are designed to be portable, and usually can be rolled up for storage and transport between yoga sessions. Typical yoga mats have a single layer construction, often made from foam. Such mats however may not provide sufficient traction for use during yoga due to the shear forces exerted on the surface of the mats by yoga practitioners.

SUMMARY

The present invention is a patterned yoga mat having an upper surface 102 and a lower surface 104 which includes a surface layer 1, a first medial layer (interlayer) 2, a second medial layer (interlayer) 3 and a bottom layer 4. The surface layer 1 is a PVC film layer having an upper surface 12 and a lower surface 14, and the first medial layer 2 is a micro-foam layer having an upper surface 22 and a lower surface 24. The lower surface of the surface layer 1 covers and adheres to the upper surface 22 of the first medial layer 2. The second medial layer 3 is a PVC foam sheet having an upper surface 32 and a lower surface 34, with the lower surface 24 of the first medial layer 2 covering and adhering to the upper surface 32 of the second medial layer. The bottom layer 4 is a PVC foam sheet having an upper surface 42 and a lower surface 44, with the lower surface 34 of the second medial layer 3 covering and adhering to the upper surface 42 of the bottom layer. A plurality of ridges 106 are formed in the surface layer 1 and the first medial layer 2, thereby forming a traction pattern on the upper surface of the yoga mat.

Preferably, the surface layer 1 is a transparent PVC film, the first medial layer 2 and the second medial layer 3 have a first color, and the bottom layer has a contrasting second color, so that a user can distinguish between the upper surface and lower surface of the yoga mat. The pattern 5 of the mat can be formed by an array of ridges 106 comprising lateral ridges and longitudinal ridges. Preferably, each of the ridges 106 has a height above an adjacent groove 108 of between 0.8 mm and 0.9 mm. The yoga mat can have a thickness of between 8 mm and 9 mm. The surface layer 1, the first interlayer 2, the second interlayer 3, and the bottom layer 4 can be adhered together by hot pressing, and in some embodiments the pattern 5 on the surface layer 1 and the first medial layer 2 can be formed by a vacuum forming process.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation view of the present yoga mat;

FIG. 2 is an enlarged view of the structure indicated by “I” in FIG. 1;

FIG. 3 is a top plan view of the yoga mat of FIG. 1.

The reference numbers in the figures have the following meanings:

Reference Component Number surface layer 1 upper surface of the surface layer 12 lower surface of the surface layer 24 first interlayer 2 upper surface of the first 22 interlayer lower surface of the first 24 interlayer second interlayer 3 upper surface of the second 32 interlayer lower surface of the second 34 interlayer bottom layer 4 upper surface of the bottom layer 42 lower surface of the bottom layer 44 anti-skid surface pattern 5 yoga mat 100 upper surface 102 lower surface 104 ridge 106 Groove 108

DETAILED DESCRIPTION Definitions

As used herein, the following terms and variations thereof have the meanings given below, unless a different meaning is clearly intended by the context in which such term is used.

“About” refers to a dimension or measurement which is within 10% if the indicated dimension or measurement.

“Calendering” refers to a process of forming a flowable plastic material into a film or sheet, such as by passing it between one or more pairs of counter-rotating rolls.

“Film” refers to a relatively thin and generally continuous layer of polymeric material. A film layer is generally thinner than other layers in a structure or material.

“Interlayer” refers to a layer of a structure or material which is positioned between two other layers.

“Mat” refers to a panel having a length and width significantly greater than its thickness, which can be formed from one or more layers of material.

“Micro-foam” and “micro-foaming” refer to polymer materials which contain gaseous bubbles that are generally less than 50 microns wide (typically 0.1-100 micrometers wide). Preferably, most of the bubbles in micro-foam materials are between 0.1 and 100 microns wide, for example 70%, 80%, 90%, or more of the bubbles are within this range.

“Traction” refers to the adhesive friction of a body on a surface, i.e. the tendency of a body to grip the surface.

“Vacuum forming” refers to a method of manufacturing a polymer item in which a sheet of plastic is heated to a forming temperature, stretched onto a single-surface mold, and forced against the mold by a vacuum.

The terms “above,” “below,” “upper,” “lower,” “between,” and other terms of relative position or orientation as used herein refer to a relative position of one layer with respect to other layers. The term “comprise” and variations of the term, such as “comprising” and “comprises,” are not intended to exclude other additives, components, integers or steps. The terms “a,” “an,” and “the” and similar referents used herein are to be construed to cover both the singular and the plural unless their usage in context indicates otherwise. Ranges which are described as being “between” two values include the indicated values.

Product

The present invention comprises a yoga mat composed of a surface layer 1, a first interlayer 2, a second interlayer 3, and a bottom layer 4. The surface layer 1 is preferably a PVC film covering the top of the first interlayer. The first interlayer, the second interlayer and the bottom layer are preferably PVC foam calendered sheets, of which the first interlayer 2 is a micro foaming layer, and the second interlayer 3 and the bottom layer 4 are foaming layers. The surface layer 1, the first interlayer 2, the second interlayer 3, and the bottom layer 4 can be compounded together to form a combined body by hot pressing, and an anti-skid surface pattern is formed on the surface layer and the first interlayer, such as through a vacuum forming process.

The surface layer 1 of the present yoga mat is preferably a PVC film, and is also preferably transparent so that the color of the first interlayer 2 is visible through the surface layer 1. The color or colors of the first interlayer 2 and the second interlayer 3 are preferably different from that of the bottom layer. For example, the first interlayer 2 and the second interlayer 3 can be a first color and the bottom layer can be a second color (e.g., the color of the first and second interlayers is purple, and the color of the bottom layer is black).

The first interlayer 2, second interlayer 3, and bottom layer 4 can be made from a compressible foam material, such as a pliable closed cell foam made from polystyrene, polymethacrylimide, polyvinylchloride, polyurethane, polypropylene, polyethylene, NES, and the like. Preferably, the foam layers are a PVC foam material. The thickness of each layer can be between 2 and 4 millimeters (mm). The total thickness of the present yoga mat, indicated in FIG. 2 by “h” (height), is preferably between 8 mm and 9 mm. By way of example, the length and width of the present mat can be about 180 cm long and 60 cm wide, although a range of other sizes is possible.

The present yoga 100 mat has an anti-skid pattern 5 on its upper surface 102 to promote suction or traction between the mat and a user of the mat. The pattern 5 can be a multi-directional array of ridges 106, which in the illustrated example are arranged so that portions of each ridge are parallel to portions of other ridges, and so that the same portions are disposed at right angles to portions of other ridges, thereby forming a combination of lateral ridges and longitudinal ridges. An individual ridge in the illustrated embodiment includes ends that form a 90° bend and which turn inwardly to form a 3-sided space. These ends are themselves disposed within the 3-sided space of another ridge. The different orientations of the ridges (lateral, longitudinal, and/or in other configurations) can provide shear traction in different directions, or can provide the opportunity for suction between the ridges 106 and the skin surface of a user of the mat. The texture depth of the surface pattern on the surface layer 1 and the first interlayer 2, i.e. the height of the ridges 106 (indicated in FIG. 2 by “h1”) above adjacent, lower surfaces forming grooves 108 is preferably about 1 mm, more preferably between 0.8 mm and 0.9 mm. The pattern can be formed on the surface layer 1 and the first interlayer 2 through a vacuum forming process, such as through adsorption onto a suction pattern roller. In another example, the pattern is pre-printed on heat transfer paper, and then the pattern on the heat transfer paper is transferred to the surface layer 1 and first interlayer 2 by a hot stamping machine.

In a preferred embodiment, the first interlayer, the second interlayer and the bottom layer are PVC foam calendered sheets, and the overall thickness of the mat can be as large as 8 mm to 9 mm, thus ensuring improved flexibility and elasticity. The depth of the surface pattern of the mat can be as large as 0.8 mm to 0.9 mm in order to ensure improved anti-skid performance. The first interlayer is preferably a micro-foaming structure, which has better anti-vibration and buffering effects, thus improving the feel of the mat to a user. The surface layer is also preferably a PVC film in order to make it more convenient for cleaning and maintenance. The combination of a surface layer of PVC transparent film, and first interlayer and second interlayer having contrasting colors (such as purple black), helps users to identify the upper and lower sides of the mat. The present mat therefore solves the problems of poor flexibility, elasticity and anti-skid performance of existing PVC yoga mats through the use of a composite structure of multi-layered PVC foam calendered sheets and a ridged surface structure.

Example

A PVC yoga mat having suction pattern and composed of a surface layer, a first interlayer, a second interlayer and a bottom layer is formed. The surface layer is a PVC film covering the top of the first interlayer. The first interlayer, the second interlayer and the bottom layer are PVC foam calendered sheets, of which the first interlayer is a micro foaming layer, and the second interlayer and the bottom layer are foaming layers. The surface layer, the first interlayer, the second interlayer and the bottom layer are compounded into one body by hot pressing, and an anti-skid surface pattern is formed on the surface layer and the first interlayer through a vacuum forming process.

The surface layer of the PVC yoga mat is a PVC transparent film. The total thickness of the PVC yoga mat is between 8 mm and 9 mm, and the depth of the anti-skid surface pattern on the surface layer and the first interlayer is between 0.8 mm and 0.9 mm.

The examples set forth herein are provided to illustrate certain concepts of the disclosure. The apparatus, devices, or components illustrated above may be configured to perform one or more of the methods, features, or steps described herein. Those of ordinary skill in the art will comprehend that these are merely illustrative in nature, and other examples may fall within the scope of the disclosure and the appended claims. Based on the teachings herein those skilled in the art should appreciate that an aspect disclosed herein may be implemented independently of any other aspects and that two or more of these aspects may be combined in various ways. For example, an apparatus may be implemented or a method may be practiced using any number of the aspects set forth herein. In addition, such an apparatus may be implemented or such a method may be practiced using other structure, functionality, or structure and functionality in addition to or other than one or more of the aspects set forth herein. The various features and processes described above may be used independently of one another, or may be combined in various ways. All possible combinations and sub-combinations are intended to fall within the scope of this disclosure. In addition, certain steps or features may be omitted in some implementations. All patents, patent publications, and other publications referred to herein are incorporated by reference in their entireties. 

What is claimed is:
 1. A patterned yoga mat having an upper surface and a lower surface and comprising a surface layer, a first medial layer, a second medial layer and a bottom layer, wherein: the surface layer is a PVC film layer having an upper surface and a lower surface; the first medial layer is a micro-foam layer having an upper surface and a lower surface, wherein the lower surface of the surface layer covers and adheres to the upper surface of the first medial layer; the second medial layer is a PVC foam sheet having an upper surface and a lower surface, wherein the lower surface of the first medial layer covers and adheres to the upper surface of the second medial layer; the bottom layer is a PVC foam sheet having an upper surface and a lower surface, wherein the lower surface of the second medial layer covers and adheres to the upper surface of the bottom layer; and a plurality of ridges are formed in the surface layer and the first medial layer, thereby forming a traction pattern on the upper surface of the yoga mat.
 2. The yoga mat of claim 1, wherein the surface layer is a PVC transparent film.
 3. The yoga mat of claim 1, wherein the first medial layer and the second medial layer have a first color and the bottom layer has a contrasting second color.
 4. The yoga mat of claim 1, wherein the pattern is formed by an array of ridges, the array comprising lateral ridges and longitudinal ridges.
 5. The yoga mat of claim 1, wherein each of the ridges 06 has a height above an adjacent groove of between 0.8 mm and 0.9 mm.
 6. The yoga mat of claim 1, wherein the yoga mat has a thickness of between 8 mm and 9 mm.
 7. The yoga mat of claim 1, wherein the surface layer, the first interlayer, the second interlayer and the bottom layer are adhered together by hot pressing.
 8. The yoga mat of claim 1, wherein the pattern on the surface layer and the first medial layer is formed by a vacuum forming process. 